Box



Oct. 17, 1967 L. F. TAYLOR, JR 3, I

BOX

Filed Oct. 22, 1965 2 sheets sheec 1 FIG].

7 F. TAYLOR, JR

BOX

Filed Oct. 22, 1965 2 Sheets-Sheet 2 United States Patent Ofilice 3,347,448 BOX Leonard F. Taylor, In, 4036 Cook, St. Louis, Mo. 63113 Filed (lot. 22, 1965, Ser. No. 502,140 9 Claims. (Cl. 229-34) ABSTRACT OF THE DISCLOSURE A box comprises two multi-ply ends and two side walls projecting upwardly from a bottom. The ends of the box each comprise two flaps positioned in face-to-face relation and constituting the inside plies of the ends. One of the flaps at each end is attached to one side wall and the other flap is attached to the other side wall. Each flap has an integral tab hinged at one side to the flap. Each tab at an end of the box projects through openings formed by cutting the tabs in the flaps to interlock the tabs and thereby hold the flaps in assembled relation. Two panels at each end of the box constitute the outer and inner plies of the box ends. The end panel is abut the tabs and hold the ends assembled. The top edge of each inner panel is connected to the top edge of the outer panel at the same end of the box. Each inner panel is wider than the spacing between the sides and is held in position by frictional engagement with the sides.

Among the several objects of this invention may be noted the provision of a box or carton which may be assembled from a prepared blank without requiring glue, tape or other fastening means for holding the box assembled; the provision of a box having improved means for holding portions of the box in their assembled relation; the provision of a box having a rnulti-ply wall with plies of the wall being interlocked; the provision of such a box in which the interlocking structure is hidden from view when the box is fully assembled, and wherein the interlocking structure will not be inadvertently released after the box is fully assembled; and the provision of a very strong box construction suitable for carrying a heavy load, the box being easily disassembled and folded flat for return to a packer, bottler, etc. Other objects and features will be in part apparent and in part pointed out hereinafter.

The invention accordingly comprises the constructions hereinafter described, the scope of the invention being indicated in the following claims.

In the accompanying drawings, in which several of various possible embodiments of the invention are illustrated.

FIG. 1 is a view of a flat blank from which a box of this invention may be assembled;

FIG. 2 is a fragmentary perspective illustrating initial steps in assembly of the box from the FIG. 1 blank;

FIG. 3 is an enlarged fragmentary section illustrating interlocking of plies in an end wall of the box during assembly;

FIG. 4 is an enlarged fragmentary longitudinal section through the box showing the end walls in two stages of assembly;

FIG. 5 is a perspective of a completed box manufactured according to the invention; and

FIG. 6 is a fragmentary perspective of a modified blank used for assembling a box according to the invention.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Referring to the drawings, a box of this invention may be manufactured from corrugated cardboard or other suitable materials and comprises a bottom 1, a pair of parallel sides 3, ends 5 and a top shown generally at 7 which is made up of two sections designated 7a and 7b.

3,347,448. Patented Oct. 17, 1967 Referring more particularly to FIG. 1 of the drawings, the box bottom 1 is located centrally of a boxboard blank from which the box is formed and it is joined to the rectangular sides 3 by parallel hinge lines or score lines 9 so that the sides can be swung upwardly along the weakened lines 9' into their assembled position in planes perpendicular to bottom 1. The sections 7a and 7b of top 7 are joined to the edges of sides 3 opposite from the bottom panel 1 along score or weakened lines designated 11. Along the outer edge of top section 7a. there is a narrow flap 13a which may be folded along a hinge line 15 for tucking the flap into the box as explained later. Flap 13a is slightly narrower than top section 7a as illustrated in FIG. 1. A similar fiap 13b is joined to top section 7b along a hinge line 15.

Parallel score lines 17 extend the full length of the blank at the ends of bottom 1. Sides 3 of the box are hinged along score lines 17 to rectangular flaps 19a, 19b, 19c and 19a. The flaps 1911-19d constitute the inside plies of end walls 5 of the assembled box. There is a threesided cut or slit 21 in flap 194: which comprises two spaced parallel portions joined along one end thereof. This cut 21 forms a locking tab 23a which may be pivoted along a hinge line 25 between end portions of the cut 21. In a similar manner, flaps 19b, 19c, 19d are provided with cuts 21 forming tabs 23b, 23c and 23d, respectively, of the same size and shape hinged to the flaps along score lines 25. It will be observed that in the Hat blank as viewed in FIG. 1 the hinge lines 25 in panels 19a and 19d for tabs 23a and 23d are located at the top edge of tabs 23a and 23d and that the hinge lines 25 for tabs 23b and 23c are located along the lower edge of the tabs. With this arrangement, when the box is erected the hinge lines 25 for the tabs 23a and 23c are at the upper edge of the tabs and the hinge lines 25 for tabs 23b and 23d are at the lower edges of the tabs. The tabs 23a-23d are arranged on the flaps so that they are in face-to-face relation in the ends of the assembled box. This permits the desirable interlocking of the tabs described later.

Hinged to the bottom 1 along score lines 17 are end sections generally designated 27. Each section 27 comprises a panel 27a joined by the score lines 17 to the bottom 1 and which constitutes the outer ply of the ends 5 of the assembled box. Sections 27 have a panel 27b which constitutes the inner ply of the ends of the box. Along the edges of panels 27b there are narrow triangular edge portions 27c joined to portions 27]; by hinge lines 29. The outer portions of panels 27b (including the width of the triangular portions 270) are wider than the width of b0ttom 1 of the box. The end sections 27 have narrow strips 27d which are joined by hinge lines 31 to panels 27a and joined by hinge lines 33 to panels 27b. Strips 27b constitute ledges in the assembled box on which the top panels 7a and 7bof the top rest.

In making up a box from the blank, the side 3 shown at the top in FIG. 1 is folded upwardly about the respective hinge line 9 and the flap 19a is folded inwardly along the respective score line 17 until they are substantially perpendicular to bottom 1 and to each other as shown in FIG. 2. Then the side 3 shown at the bottom of FIG. 1 is folded upwardly on the respective hinge line 9 and the flap 19d attached to it is swung inwardly until they are perpendicular to bottom 1 and to each other. Flap 19d is thus located exteriorly of the flap 19a as illustrated in FIGS. 24.

Then the tabs 23a and 23a are interlocked as illustrated in FIGS 3 and 4. With the flaps 19a and 19d located in face-to-face relation, the tabs 23a and 23d are aligned back-to-back and since they are of the same size either of the tabs may be forced through the hole in the adjacent panel. Tab 23a may thus be swung about its hinge 25 through the hole in panel 19d formed by the cut 21 which produced tab 23d through its FIG. 3 to its FIG. 4 position where it overlies the outer surface of flap 19d. As this occurs the tab 23d will be forced outwardly to its FIG. 3 dotted line position to permit passage of tab 23a. Next tab 23d is swung from its dotted line position through the holes formed by cuts 21 forming the tabs 23d and 23a into the interior of the box through the position shown in solid lines in FIG. 3 to the position shown in FIG. 4 where it overlies the inner surface of flap 1901.

End panel 27a is then swung upwardly on hinge line 17 until it overlies the exterior surface panel 19d and the outer surface of ta-b 23a. This upward swinging movement of panel 27a may be used for moving tab 23a from it FIG. 3 to its FIG. position (as shown for tab 230 at the right of FIG. 4). The left-hand end section 27 is then hinged along lines 31 and 33 and the outer panel 27b is swung clockwise (as viewed in FIGS. 3 and 4) until it is located inside the box between sides 3 overlying the inner face of flap 19a and tab 23d. This locates the ledge portion 27d of the end section 27 across the upper edges of panels 19a and 19d and forms a shelf extending above the upper edge of panels 1% and 19d from one side 3 to the other side 3 of the box end. As panel 27b is swung into the box, its triangular edge portions 270 engage sides 3 and are forced out of the plane of the central portion 27b into the position illustrated in FIG. 4 of the drawings where they are firmly wedged against sides 3. This occurs because the combined width of the portion 27b and both triangular portions 270 is wider than the spacing between side walls 3 by the width of the triangular portions. The triangular portions 27c when wedged against the sides 23 of the box as shown in FIG. 5 tightly hold the portion 27b against counterclockwise movement from its FIG. 5 position. Flaps 19a, 19d (and sides 3) cannot move sideways from their FIG. 5 position at this time since section 27 holds taps 19a, 19d in their FIG. 4 interlocked position The frictional engagement between triangular portion 27c and sides 3 of the box is sufficient to prevent inadvertent disassembly of the box.

Flaps 19b and 190 are arranged at the other end of the box so that flap 19b is outside of flap 190 as shown in FIG. 4. Tabs 23b and 230 are then interlocked in the same manner as that previously described with tab 230 swinging from the interior of the box through the flap 19b to a position outside flap 19b and it is held in this position by the other end panel 27:: swinging upwardly on hinge line 17 to close the end of the box. Tab 23b swings through flap 19c and is held against the inside of the flap by end panel 271). When assembly of the ends is completed the cover portions 7a and 7b may be swung over the open top of the box along hinge lines 11 and the flaps 13a and 13b inserted into the box by folding along lines 15. The edge portions of top panels 701 and 7b rest on and are supported by the ledges 27d at the ends of the box thus holding the top flap.

It will be observed that each end of the box has four plies substantially throughout its width and height including panel portions 27a, 27b and two flaps therebetween. The construction of the box is such that when the box is made of corrugated material the corrugations of panels 27a, 27b will be perpendicular to the corrugations of the flap therebetween. These features produce a very strong box capable of receiving and carrying very heavy loads without damage to the end walls of the box. This is particularly desirable when the box is carrying heavy merchandise such as beer since the loaded boxes or cases of beer will then frequently be carried from one end of the box through a hand hole (not shown) and substantially the entire weight of the load must be borne by the other end of the box.

The box of the invention may be entirely assembled at the point of manufacture of articles carried by the box or at the point where they are loaded into the box. No staples, glue, tape or other fastening means are required to hold the box in its assembled position due to the manner in which it is constructed and assembled. When the box has been unloaded it may be disassembled or unfolded to its FIG. 1 condition by reversing the assembly steps set forth hereinbefore. The friction between the triangular portions 270 and the side walls 3 of the box is easily overcome by hand. Thus when the carton or box is being used for carrying disposable beer bottles (or other beverage bottles) and the bottles have been removed from the box, it may be unfolded flat and returned to the bottler. By unfolding them flat less space is required for storing the used cartons and for transporting them to the bottler.

The blank shown in FIG. 1 is made from a single piece of cardboard or other material. If desired it may be made from several different pieces of cardboard. For example, it will be observed that the bottom 1, sides 3, flaps l9a19d and the major portions of the panels 27a could all be formed from a single rectangular piece of cardboard by forming the necessary slits or cuts and the weakened lines 9 and 17. The top sections 7a, 7b including the flaps 13a and 13b attached thereto, the panel sections 27b, 27c, ledge portions 27d and the outer portions of panels 27a may be separately formed and attached to panels 27a and sides 3 by staples, glue or other suitable fastening means. This is illustrated in FIG. 6 of the drawings which shows an end panel 271;, ledge 27d and a portion of panel 27a connected by means of staples 34 to the inner portion of panel 27a. With this arrangement the box may be more economically produced than from a one piece blank since there is very little or no scrap or waste material resulting from formation of the blank.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

What is claimed is:

1. A box construction comprising a bottom, a pair of side walls projecting upwardly from the bottom and a pair of ends projecting upwardly from the bottom between the side walls, at least one of said ends of the box comprising two flaps positioned in face-to-face relation and extending across the end of the box from one side to the other side, one flap being attached to one side wall and the other flap being attached to the other side wall, a tab projecting through said flaps for locking the flaps together thereby preventing separation of the side Walls and the flaps until the locking tab is unlocked, a panel at said end of the box overlying one of the flaps and the tab to hold the locking tab in its locked position, each of the flaps having an opening through it aligned with an opening of the same size and shape in the other flap, said tab being hinged to the inner one of said flaps along one edge of the opening therein and having a portion positioned against the face of the outer one of said flaps opposite from said inner flap, and a second tab hinged to the outer flap along one edge of the opening therein and having a portion positioned against the face of the inner flap opposite from the outer flap.

2. A box construction as set forth in claim 1 wherein said panel is hinged to the box bottom and extends upwardly therefrom at said one end and overlies said outer flap and the first tab, and there is a second panel overlying the inner flap and the second tab for holding the second tab in position against the inner fiap.

3. A box construction as set forth in claim 2 wherein the second panel is wider than the spacing between the sides, and the second panel has at least one side edge portion wedged against the adjacent side of the box for holding the panel in position inside the box.

4. A box construction as set forth in claim 2 further comprising a ledge joined to said panels and extending across the top of said one end of the box, and the box has a top section attached to a side of the box and adapted to rest on said ledge when in a closed position over the box bottom.

5. A box formed from a boxboard blank having a rectangular bottom having sides and ends, rectangular side walls extending upward from the sides of the bottom panel, each side wall having a rectangular flap at each end thereof, the two flaps at each end of the box being folded inward to extend over the respective end of the bottom and lying in face-to-face relation one inside the other, outer end panels extending upward from the ends of the bottom on the outside of said flaps, inner end panels folded down from the upper ends of the outer end panels on the inside of said flaps and being wedged into the box, each of said flaps having a tab struck out therefrom leaving a hole in the flap, the tab of each inside fiap being interlocked with the respective outer flap through the hole in the latter, and the tab of each outer flap being interlocked with the respective inner flap through the hole in the latter.

6. A box formed from a boxboard blank having a rectangular bottom having sides and ends, rectangular side walls extending upward from the sides of the bottom panel, each side wall having a rectangular flap at each end thereof, the two flaps at each end of the box being folded inward to extend over the respective end of the bottom and lying in face-toface relation one inside the other, outer end panels extending upward from the ends of the bottom on the outside of said flaps, inner end panels folded down from the upper ends of the outer end panels on the inside of said flaps and being wedged into the box, one of said flaps having a tab struck out therefrom leaving a hole in the flap, the tab being interlocked with the other flap through a hole in the latter.

7. A box as set forth in claim 6 wherein the other flaphas a tab struck out therefrom leaving a hole in the flap, the tab of the other flap being interlocked with said one flap through a hole in the latter.

8. A box as set forth in claim 6 wherein the other flap has a tab struck out therefrom leaving a hole in the flap, the tab of the other flap being interlocked with said one flap through the hole therein resulting from striking out the tab in said one flap, and the tab of said one flap is interlocked with the other flap through the hole left by striking out the tab of said other flap.

9. A box as set forth in claim 8 wherein the outer and inner end panels engage the tabs interlocked in the flaps for holding them in their interlocked position.

References Cited UNITED STATES PATENTS 2,105,057 1/1937 Sharpe 229-34 2,220,972 11/1940 Mairson et al. 22934 2,741,415 4/ 1956 Meitzen 229-36 JOSEPH R. LECLAIR, Primary Examiner. R. PESHOCK, Assistant Examiner. 

1. A BOX CONSTRUCTION COMPRISING A BOTTOM, A PAIR OF SIDE WALLS PROJECTING UPWARDLY FROM THE BOTTOM AND A PAIR OF ENDS PROJECTING UPWARDLY FROM THE BOTTOM BETWEEN THE SIDE WALLS, AT LEAST ONE OF SAID ENDS OF THE BOX COMPRISING TWO FLAPS POSITIONED IN FACE-TO-FACE RELATION AND EXTENDING ACROSS THE END OF THE BOX FROM ONE SIDE TO THE OTHER SIDE, ONE FLAP BEING ATTACHED TO ONE SIDE WALL AND THE OTHER FLAP BEING ATTACHED TO THE OTHER SIDE WALL, A TAB PROJECTING THROUGH SAID FLAPS FOR LOCKING THE FLAPS TOGETHER THEREBY PREVENTING SEPARATION OF THE SIDE WALLS AND THE FLAPS UNTIL THE LOCKING TAB IS UNLOCKED, A PANEL AT SAID END OF THE BOX OVERLYING ONE OF THE FLAPS AND THE TAB TO HOLD THE LOCKING TAB IN ITS LOCKED POSITION, EACH OF THE FLAPS HAVING AN OPENING THROUGH IT ALIGNED WITH AN OPENING OF THE SAME SIZE AND SHAPE IN THE OTHER FLAP, SAID TAB BEING HINGED TO THE INNER ONE OF SAID FLAPS ALONG ONE EDGE OF THE OPENING THEREIN AND HAVING A PORTION POSITIONED AGAINST THE FACE OF THE OUTER ONE OF SAID FLAPS OPPOSITE FROM SAID INNER FLAP, AND A SECOND TAB HINGED TO THE OUTER FLAP ALONG ONE EDGE OF THE OPENING THEREIN AND HAVING A PORTION POSITIONED AGAINST THE FACE OF THE INNER FLAP OPPOSITE FROM THE OUTER FLAP. 